Papers by Author: Hiroyuki Hosokawa

Abstract: TiC based cermet is a candidate material for alternatives of WC-Co used in tools/dies. Ordinary, Ni and Co, etc. are used as a metal binder of TiC based cermet. They are kinds of rare metals, therefore it is desired that metal binders are also replaced with the ubiquitous materials. FeAl intermetallic alloys are one of candidate materials of alternative rare metal binder made from ubiquitous materials. FeAl is well-known as an extremely resistance material to corrosion under oxidizing atmospheres, sulfidizing atmospheres, and in molten salts. Combination of intermetallic and carbide, the hardness is very high, but it would be brittle. In this work, TiC-FeAl alloys are made by wet milling and pulsed electric current sintering to improve transverse rupture strength while the hardness is kept. We achieved that TiC-40 vol. % (Fe-40 at. % Al) alloy with hardness of 17.7 GPa and T.R.S. of 1.9 GPa.

Abstract: With the aim of developing a durable tool for friction stir processing (FSP) of cast iron, the durability of a Ti (C,N)-Ni cermet tool has been investigated and compared with that of a WC-Co cemented carbide tool. Results of exposure tests in air revealed that the WC-Co cemented carbide sample oxidized rapidly above 973 K, whereas the cermet material showed little oxidization even after holding at a temperature of 1103 K. When these tools were used for the FSP of cast iron surfaces, it was found that an oxide layer of over 100 μm was generated on the lateral faces of the WC-Co cemented carbide tool after it was used to work a length of 400 mm. In contrast, a thin oxide layer of only 5 μm was generated after the cermet tool worked a length of 2400 mm. Cross sections of the iron casts (FC250) subject to FSP using these tools showed that in a bowl-shaped region approximately 1.5 mm deep the initial pearlite structures changed to martensite structures. The martensite structures in this region had a Vickers hardness of 600 to 800 HV, while that of the initial pearlite structure was about 280 HV.

Abstract: The fracture toughness and hardness of Ti (C_0.7N_0.3)-19Mo₂C-xNbC-24Ni cermets (x = 0, 5, 20) were studied. Fracture toughness of 5 NbC was the largest, and it of 20 NbC was the lowest. The microstructures of all the cermets consisted of Ti (C,N) and solid soluted Ti (C,N) hard phase, and Ni binder phase. The solid soluted Ti (C,N) surrounded Ti (C,N), namely, core-rim structures were observed in 0NbC and 5NbC. On the other hand, the isolated Ti (C,N) and solid soluted Ti (C,N) were observed in 20NbC, as a result of the phase separation between Ti (C,N) core and solid soluted Ti (C,N).

Abstract: In this presentation, we show some experimental results of binder-free WC with Nano WC sintered by Pulsed Electric Current Sintering (PECS) process also known as Field Assisted Sintering Technology (FAST). The particle size of WC powder is almost 80 nm. These binder-free WC have extremely hardness and stiffness. However, these mechanical properties are dependent on the sintering condition, e.g., maximum temperature, applied presssure, etc. We show some relationship between mechanical properties and sintering condition to improve to sinter the binder-free WC

Abstract: The behavior of hardmetals under cyclic loads is investigated. Unnotched specimens were employed to obtain practical information regarding fatigue in hardmetals. All the tested hardmetals exhibit an increase in the number of cycles until failure with a decrease in the maximum stress, i.e., the hardmetals exhibit a high fatigue sensitivity. The fatigue strength increases with the cobalt content. Although distinct fatigue limits, as observed in metals, cannot be observed, the calculated fatigue limit stress at 107 cycles is found to be approximately 70% of the flexural strength, and the stress value exhibits a linear relationship with the flexural stress.

Abstract: To investigate sliding friction and wear behaviors of WC–Co/WC–Co pairs containing different WC grain sizes, the ball-on-disc test in air were carried out for WC-Co containing WC grain sizes of 0.5 μm (F.G.) and 1.5 μm (C.G.). The results show that the wear volume of F.G. pin for F.G. pin/C.G. disc is larger than that of F.G. pin for F.G. pin/F.G. disc due to higher friction coefficient, and the surfaces after wear test are richer in oxygen compared to those before test. Furthermore, the wear debris, which is composed of nona-scale grains, after the wear test are remarkably richer in oxygen than to those before test. The diffraction pattern reveals sharp ring

Abstract: In this paper, we show some experimental results of binder-free WC sintered by Pulsed Electric Current Sintering (PECS) also known as Field Assisted Sintering Technology (FAST). These binder-free WC have extremely high hardness and stiffness. However, these mechanical properties are dependent on the sintering condition, e.g., maximum temperature, applied pressure, etc. We show some relationship between mechanical properties and sintering condition to improve to sinter the binder-free WC.

Abstract: Superplastic forming characteristics of AZ31 Mg alloy recycled by solid-state process were investigated. Cylindrical scraps and machined chips were recycled by hot extrusion and hot rolling in air. As a result of tensile test, elongation to failure of the specimens recycled from small and large cylindrical scraps was almost the same as that of the rolled specimen from a virgin ingot. On the other hand, the specimen from machined chips had much lower elongation at elevated temperatures. The oxygen concentration of the specimen recycled from machined chips showed about 60 times higher value compared with that of the other specimens. In superplastic forming tests, the specimen from small and large cylindrical scraps exhibited excellent formability similar to the rolled specimen from a virgin ingot. However, the specimen from machined chips showed poor formability. Thus, oxide contamination adversely affected the formability of recycled Mg alloy.

Abstract: Superplastic behavior and cavitation were investigated for WC-15 mass % Co cemented carbides with the WC grain sizes of 0.7 µm (A) and 5.2 µm (B), WC-10 mass % Co cemented carbide with the WC grain size of 1.5 µm (C) and WC-5 mass % Co cemented carbides with the WC grain sizes of 0.5 µm (D) and 2.5 µm (E) by tensile tests at 1473 K. WC contiguity were 0.51, 0.31, 0.27, 0.56 and 0.49, respectively. The large elongations about 200 % were obtained for the B and the C having smaller values of WC contiguity compared to the other cemented carbides. The values of cavity volume fraction for them were less for the other cemented carbides, furthermore, cavities formed at WC/WC interfaces. Therefore, it is noted that the distribution of the Co phase is important for superplasticity of the cemented carbides.

Abstract: Blow forming characteristics of 5083 Al alloy and AZ31 Mg alloy recycled by solid state recycling were investigated. Scraps with different volume were recycled by hot extrusion and hot rolling in air. Oxide layers, which were contaminants from scrap surface, were distributed parallel to the extrusion direction in the recycled specimens. In the blow-forming test, the specimen from smaller scraps exhibited lower formability. The oxygen concentration in the recycled specimens was approximately proportional to the total surface area of scraps in the recycled specimen per unit volume. The low formability of the recycled specimens is likely to be attributed to contamination level of oxide.